User’s Manual forNozzle Cleaning Station(TKS-Z series)

TOKIN CORPORATION

Please send this manual to the end user.
Document number: TS1011M01_6

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MANDATORY•This user ’s manual contains important information about safety issues, mechanicalspecifications, and maintenance that are required when you operate the wire
cutter, the nozzle cleaner, and the anti-spatter sprayer.

Read this manual

thoroughly to obtain a clear understanding before proceeding to any work.

CAUTION•Drawings in the manual may be shown without a cover or an enclosure for
explanation purposes.

Be sure to return the cover or the enclosure in place

before operating this unit.
•Drawings and photos attached to the manual are representative and may differ
from the actual product.
•The manual is revised as appropriate, when the product is updated and thespecification is changed, for the purpose of improving manual’s usability.

The

revision is controlled by the document number on the front or last page.
•If the manual was damaged or lost and you need to have a new one, pleasecontact us by the address on the last page and let us know the document number
on the front or last page.
•Do not modify the product.

Our warranty does not cover the customer sidemodification, and we are not liable for any accidents caused by the customer-sidemodification.

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SAFETY PRECAUTION
Read this manual and all attached documents thoroughly before proceeding to any
work (i.e. installation, operation, maintenance).

Make a clear understanding of themechanical, safety and other precautionary issues, and follow the instructions.

DANGER: indicates that there is a risk of death or serious

CAUTION: indicates that there is a risk of injury if handledinjury if handled erroneously.

erroneously.

MANDATORY: indicates that it is absolutely necessary.

PROHIBITED: indicates that it must not be done.

Items in the “CAUTION” can cause serious accidents depending on the situation.
These signs all introduce important instructions that you must follow.

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TABLE OF CONTENTS

1. PRODUCT SUMMARY ................................................................ 5
2. PRODUCT CONTENTS .............................................................. 5
3. TECHNICAL SPECIFICATIONS ............................................. 6
4. SETTING UP ................................................................................... 64.1 Installation of the Nozzle Cleaning Station ................................... 64.1.1 Installation site of the nozzle cleaning station ...................... 64.1.2 Main unit assembly ................................................................... 74.1.3 Main unit installation ................................................................ 84.1.4 Part installation ....................................................................... 104.2 Air Tube Connection and Electric Wiring ..................................... 114.3 Nozzle Cleaning Workflow ............................................................ 124.3.1 Wire-cutting ............................................................................. 124.3.2 Nozzle inner wall cleaning ..................................................... 134.3.3 Anti-spatter spraying .............................................................. 134.4 Danger/Caution in use of Nozzle Cleaning Station ..................... 144.5 Maintenance .................................................................................. 144.5.1 Replacement of wire-cutting blade ........................................ 145. Dimensions .................................................................................. 195.1 Mechanical Construction and Dimensions .................................. 195.2 Consumable Parts ......................................................................... 194

1. PRODUCT SUMMARY
This product performs wire cutting, nozzle cleaning, and anti-spatter spraying.
This product is intended for use with a welding robot.

2. PRODUCT CONTENTS
Check that the following items are included in the package.
Part NameQty.

TKS-Z1

TKS-Z2

TKS-Z3

1

Station assembly

1xxx

2

Waste bottle

1xxx

3

Anti-spatter (nozzle coat) solution

1xxx

4

Holed bottle cap

1xxx

5

Trash container

1xxx

6

Nozzle cleaner head

1xxx7Column

1---

x

x

8L-bracket

6---

x

x

9Cage nut

6---

x

x

10 Hexagon bolt (M8 x 20)

6---

x

x

113---xx

12 Spring washer (M8)

9---

x

x

13 Flat washer (M8)

9---

x

x

14 Bottle holder

1---

---

x

15 Regulator

2---

---

x

16 Solenoid valve (EXA-C6-02GSB-3)

1---

---

x

17 Solenoid valve (3GA110-C6-E2-3)

1---

---

x

18 Cage nut

2---

---

x

19 Hexagon bolt (M8 x 15)

2---

---

x

20 Spring washer (M8)

2---

---

x

21 Flat washer (M8)2------xHexagon bolt (M8 x 15)

Column type: TKS-Z2, Z3No-column type: TKS-Z15

3. TECHNICAL SPECIFICATIONS
Items
Nozzle cleaner

Specifications

Pneumatic pressure

0.2 to 0.5 [MPa]Applicable nozzle diameter

Inside diameter: ø16 (standard)
Cleaner heads are available in various
diameters to suit your nozzle size.

Wire cutter

Cutting ability

Solid wire: ø1.6 max
Flux wire: ø3.2 max(When air pressure is 0.6 Mpa)

Pneumatic pressure

0.3 to 0.8 [MPa]Wire cutter power source

24 VDC, 75 mA max(Solenoid valve)
Anti-spatter

Pneumatic pressure

0.2 to 0.4 [MPa]sprayer

0.2 MPa is recommended.
Applicable nozzle diameter

Outer diameter: ø16 to 26

4. SETTING UP
4.1 Installation of the Nozzle Cleaning StationDANGER•Turn off the power of the robot controller before installing the nozzle cleaning
station, otherwise bodily injury or equipment breakdown may occur.
•Install the nozzle cleaning station properly and firmly so as not to fall, otherwise
bodily injury or equipment breakdown may occur.

4.1.1 Installation site of the nozzle cleaning station
Install the main unit of the nozzle cleaning station to the place that satisfies
the following conditions.
(1) The torch tip of the robot can reach the main unit.
(2) There is no interference between the main unit and other hardware (jigs,works, etc).
(3) A relative position between the main unit and the robot is not changed byexternal factors such as vibration.
(4) The main unit does not receive oil and spatters.

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4.1.2 Main unit assembly
The TKS-Z series nozzle cleaning station has three models: TKS-Z1, TKS-Z2,and TKS-Z3.
If you purchased TKS-Z2 and TKS-Z3, follow the next instructions for setup.
1) Attach the bottle holder to the left side as you see the column’s sticker facein the front.

(TKS-Z3)

The bottle holder should be fixed to about 200 mm from the column’s top end.
Parts to be used: Two hexagon bolts (M8 x 15), two spring washers, two flatwashers(TOP)(BOTTOM)

Bottle holder<Front view>(TOP)(BOTTOM)<Elevational view>

2) Fasten the supplied L-bracket to the column.

(6 places total: top andbottom)
Parts to be used: Hexagon bolts (M8 x 20), spring washers, flat washers,
cage nuts
Hexagon bolt (M8 x 20)
Spring washer

L-bracket

Flat washer

Cage nut3) Fasten the station plate to the column.
Parts to be used: Hexagon bolts (M8 x 15), spring washers, flat washers

74.1.3 Main unit installation<Column type (TSK-Z2 and TKS-Z3)>
Securely fasten the column, which you put brackets on, to the facility
foundation base with M8 anchor bolts etc.

(3 places)

Dimensions

3-L-bracket<Top plan view>8<No-column type (TKS-Z1)>
1) Fasten the station plate by using four bolt-holes in the station plate.
Dimensions2) Use three M8 bolt holes to fix station onto a stand.
A stand should not interfere with the shaded area.

Be sure that the main unit is installed firmly.

If the installation is loose,

operations such as wire cutting, nozzle cleaning, anti-spatter spraying
cannot be performed normally.

94.1.4 Part installation
After the main unit is properly installed, install other parts by the followingmanner.
1) Attach the trash container and nozzle cleaner head.

*Follow the next setup procedures if you purchased TKS-Z3.
2) Place the anti-spatter bottle and the waste bottle into the bottle holder.
Connect the waste tube to the waste bottle, and the feeding tube to theanti-spatter bottle.

(See the label on the tube.)*Place the holed bottle cap (supplied) onto the anti-spatter bottle.
3) Connect the nozzle cleaner ’s air tube to the quick pipe fitting of the☞ FIG. 1

solenoid valve (EXA-C6-02GSB-3).

4) Connect the wire cutter ’s air tube to the quick pipe fitting of the solenoidvalve (3GA110-C6-E2-3).

☞ FIG. 25) Connect the anti-spatter sprayer ’s air tube to the quick pipe fitting of theregulator.

☞ FIG. 3

FIG. 1

FIG. 2

FIG. 3

FIG. 410

4.2 Air Tube Connection and Electric Wiring

CAUTION• Be sure to use clean air.
• Air tubes are flammable.

Do not arrange air tubes to the place where theyreceive weld spatters or high heat.
Arrange the air tube connection and the electric wiring according to thefollowing diagram.

Anti-spatter sprayerRegulator

Ø6 air tubeAirNozzle cleaner

Solenoid valve

Regulator

Connected to the robot
external output

Wire cutter

Solenoid valve

Connected to the robot
external output*TKS-Z3 is supplied with the regulator and the solenoid valve as attached to thebottle holder.
*TKS-Z1 and TKS-Z2 are not supplied with the regulator and the solenoid valve.
Please purchase them separately.

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4.3 Nozzle Cleaning Workflow
Nozzle cleaning is performed in the following order.

Teach your robot each

event sequence by referring to an example of the corresponding section.

Wire-cutting… ☞ §4.3.1Nozzle inner wall cleaning… ☞ §4.3.2

Anti-spatter spraying… ☞ §4.3.3

4.3.1 Wire-cuttingThis operation removes the bead formedon the wire tip.

See the following sequence,and create a robot program in your robot controller.
Wire-cutting position

Enter from the front of the wire cutter ①

Wire-inching

Inching position

Shift to wire-cutting position ② *③
Hold for 0.3 second (for example)

Turn on wire-cutting command **Hold for 0.5 second (for example)①②

Turn off wire-cutting command **Hold for 0.5 second (for example)

Shift upwards ③* Set the cutting position to the left backside of the upper blade.
** Carry out the wire-cutting command by the ON/OFF operation of the solenoid valve.

124.3.2 Nozzle inner wall cleaning
Spatters accumulated inside the nozzle are removed.
See the following sequence and create a robot program in your robot controller.

Shift to above nozzle cleaner ①Lower nozzle.

Turn on solenoid valve androtate cleaner head immediately after cleaner
head enters into nozzle.

Perform up-and-down movement as necessary ② *Move up nozzle and turn off solenoid valve. **Shift to above inner wall cleaner ③* Pay particular attention to the positional relationship between the cleaner tip andthe nozzle orifice so as not to damage them.
** Repeat ② and ③ as necessary

4.3.3 Anti-spatter spraying
Anti-spatter solution is sprayed to the nozzle so that spatters are prevented fromaccumulating.

See the following sequence and create a robot program in yourrobot controller.

Shift to above anti-spatter sprayer ①

Shift down ②

Hold for 0.5 second (for example)

Shift up

Shift to above anti-spatter sprayer ③13

4.4 Danger/Caution in use of Nozzle Cleaning StationDANGER• Do not touch or approach the cleaner head while the cleaner head is inoperation.

Bodily injury or equipment breakdown may occur.

If you must

touch the cleaner head in need of checking or replacing the blade, be sure toturn off the air and check that the cleaner head never moves.
• Be sure that the nozzle cleaning station is securely fixed to the facility foundation
by anchor bolts or foundation bolts.

If the attachment is loose, the nozzle

cleaning station may fall and cause bodily injury and equipment breakdown.
• Periodic maintenance must be performed by the person who has been properly
trained.

Otherwise, bodily injury or equipment breakdown may occur.

CAUTION
Keep the pneumatic pressure of the wire cutter between 0.3 and 0.8 Mpa.
Otherwise, the wire may not be cut normally and the device may be damaged.

4.5 Maintenance4.5.1 Replacement of wire-cutting blade

DANGER
Turn off the air supply before blade replacement.

Do not perform blade

replacement until you check that the blade never moves.

141) Unscrew two bolts, and remove the wire cutter cover.

Wire cutter coverBolt

2) Remove the shaft pin that holds the lower blade, and unscrew four
hexagon socket head cap bolts that fasten the cutter holder.

Then,remove the cutter holder by pulling it straight up.

Shaft pin

Cutter holder

Blade support

153) Remove the upper blade, the center pin, and the lower blade in this order.

Lower blade

Center pin

Upper blade4) Change the lower and upper blades with the new ones, and put them back
together in the order of the lower blade, the pin, and the upper blade.
*A cutting edge is formed on both sides.
If both sides have not been used, turn the blade upside down for anotheruse.

165) Insert the shaft pin and fasten the lower blade.

Return the cutter holder

to the original place and fasten them firmly with four bolts.

6) Return the cutter cover to the original place.

Now, replacement of the wire-cutting blade is complete.

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NOTE:

A cutting edge is formed on both sides. If both sides have not been used,
turn the blade upside down for another use.
V-groove is directed to the right side as a factory-shipping mode.
V-groove‘After you have turned the blade upside down, the V-groove faces the left side.
Change the blade with a new one if it does not cut well in this state.
replace the upper blade and the lower blade both at the same time.

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Be sure to5. Dimensions
5.1 Mechanical Construction and Dimensions

Nozzle cleaner
Anti-spatter sprayer
Wire cutter

5.2 Consumable Parts
Part no.

Part name

Qty.

Maker

Note

*046211Nozzle cleaner head

1

TOKIN046253

Wire cutter (upper blade and1TOKIN

1TOKIN

lower blade in pair)
046114Anti-spatter (nozzle coat) solution* Please specify the nozzle’s inner diameter when placing an order.

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User ’s Manual for Nozzle Cleaning Station
Document number: TS1011M01_6

First issue: November 01, 2010
Sixth issue: September 26, 2014

TOKIN CORPORATION
1509 Okubo-cho, Nishi-ku, Hamamatsu-Shi,
Shizuoka Japan, 432-8006
TEL: +81 (0) 53-485-5252

FAX: +81 (0) 53-485-5680

URL: http://www.tokinarc.co.jp/E-mail: trading@tokinarc.co.jp

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